Research on Shovel-Force Prediction and Power-Matching Optimization of a Large-Tonnage Electric Wheel Loader

Abstract

Nowadays, rapid development has been achieved with respect to the electric wheel loader (EWL). The operational efficiency of EWLs is affected by many factors; especially, shovel force is a very important factor. For large-tonnage EWLs, when employing empirical, formula-based methods to predict shovel force, the generated errors are significant, with errors frequently reaching levels of up to 30%. To solve this problem, a method, based on the discrete element method (DEM), to predict shovel force is put forward in this paper. The material parameters are calibrated by a backpropagation (BP) neural network learning algorithm (NNLA). The material model is inputted into multi-body-dynamics software. A simulation model to accurately predict the shovel force is created. The error between the test results and the simulation results is 7.8%, demonstrating a high level of consistency. To validate the reliability of this method, the 35-ton EWL is taken as an example for research, and the straight-line driving test and the power-matching test are conducted. While ensuring the operational efficiency of the EWLs, the power loss is also a crucial consideration. The drastic changes in shovel force often result in front-tire slippage of the EWLs. To minimize wheel slippage during the shoveling section, the matching of the electric motor was optimized. In summary, material parameters were calibrated using a combined method of BP NNLA to predicate shovel force of a large-tonnage EWL. Additionally, the power matching of the EWL has been optimized to accord with the shoveling section of the device.